nasa usli flight readiness review...connor gisburne, payload safety lead dr. david lineberry,...

NASA USLI Flight Readiness ReviewUniversity of Alabama in Huntsvil le

Charger Rocket Works

March 13, 2019

Agenda

Introductions and Team Overview

Mission Objectives

Changes Since CDR

Vehicle Overview

Payload Overview

Program ManagementSafety

Testing and Verification

Outreach

Budget

Wednesday, March 13, 2019 UNIVERSITY OF ALABAMA IN HUNTSVILLE | CHARGER ROCKET WORKS 2

IntroductionsZachary Ruta, Program Manager

Hope Cash, Safety Officer

Marcus Shelton, Chief Engineer

William Hankins, Vehicle Lead

Colton Connor, Payload Lead

Tanner Schmitt, Deputy Safety Officer

Brooklyn Kirkwood, Vehicle Safety Lead

Connor Gisburne, Payload Safety Lead

Dr. David Lineberry, Faculty Advisor

Jason Winningham, NAR/TRA Mentor, Level III Certified

Bao Ha, Graduate Student Teaching Assistant


Mission Statement

The objective of the Charger Rocket Works (CRW) team is to construct a safe and successful Level 2 high

powered rocket with deployable unmanned air vehicle as a payload through applying engineering

judgement and skills. Additionally, CRW will engage with the community in STEM education events and

promoting rocketry to diverse groups.


Mission Objectives

Vehicle: The rocket will deliver the payload to an altitude of approximately 4800 ft., descend safely and within the Mission Performance Requirements set by NASA, and be recovered in a reusable state.

Payload: The payload will deploy from the rocket, fly to a target location, and drop a beacon on target zone all while meeting the desired NASA requirements for the USLI competition.

Safety: Comprehensive safety methods will be implemented in all aspects of fabrication, testing, and launches of hardware using in-depth analysis and written procedures and checklists.

Outreach: The CRW team will meet a minimum of 200 students through hands-on activities as per the request of NASA and will promote STEM and rocketry to diverse groups.


Vehicle



Vehicle Overview

Parameter Value

Vehicle Length 124in

Body Tube Diameter 6in

Vehicle Weight 50.095lb

Motor Selection L1420R

Predicted Apogee 4982ft

Wednesday, March 13, 2019

Vehicle Overview

1

2 4

Pre-Launch

Launch

5

Drogue Deployment at Apogee

Main Deployment

3

Landing Rocket assembled Rocket placed on pad

Drogue deployment charge at apogee

Backup drogue deployment charge at apogee plus 1 sec

Motor ignited Vehicle accelerates

Main parachute deployment at 600 ft AGL

Backup main deployment at 550 ft AGL

Payload deploys Rocket recovered

UNIVERSITY OF ALABAMA IN HUNTSVILLE | CHARGER ROCKET WORKS 8

Vehicle Changes since CDR


Key Switch has been added to nose cone such that nosecone avionics can be powered on externally

Conserves battery life and ensures signal will not be lost during flight

Tracker bracket redesigned to allow more mounting surface for the avionics

Is now a 3D printed part

3D printed component infill increased from 25% to 35% to increase strength

Nose Cone and Body Tube


Body tube cut from 60in G12 fiberglass tube via wet-saw

Metal tipped 4:1 ogive nosecone purchased from Madcow

Bulkhead and key switch holes hand drilled

Upper Airframe Bulkheads


Upper airframe bulkhead functions as recovery retention system and payload attachment bulkhead

Drogue parachute attaches to upper airframe bulkhead via eyebolt

Nosecone Bulkhead functions as nosecone avionics and payload attachment bulkhead

Diameter: 6 in

Aluminum thickness: 0.25 in

Fixed to body tube with six #4-40 screws

CNC machined from 6061-T6 Aluminum

Nosecone Bulkhead

Upper Airframe Bulkhead

Coupler Coupler 13 in. long with 1 in. switch band cut from excess body tube G12 fiberglass bulkhead holes drilled using 3D jig and drill press SPST key switches used to power avionics on pad Keys not removable when system powered off Key locks printed to prevent accidental powering during transport to pad


Lower Body Tube

Cut from a 60in G12 fiberglass tube on a wet-saw

Fin slots cut using plunge router

Holes for bulkhead and fin can were hand drilled


Aft Bulkhead

Functions as recovery retention system

Main parachute attached via eyebolt

Diameter: 6 in

Aluminum thickness: 0.25 in

Fixed to body tube with 6 #4-40 screws

CNC machined from 6061-T6 Aluminum


Fins and Fin Can

Fins:

Adjusts CP for stability

G10 fiberglass sheet

Cut with wet saw

Through-wall mounting

Installed with eight #4-40 bolts per fin

Fin Can:

3D printed in-house with PLA

Fixed to airframe with eight #4-40 bolts


Thrust Plate

Transfers force from motor

CNC machined from 0.190 in. 6061-T6 Aluminum


Retention Ring

Load Path:Boost phase

Motor case

Thrust plate

Body tube

Coast phase

Retention ring retains motor


3D printed from ABS plastic

Retained the motor during coast phase of the flight

Attached to the fin can using 2 #4-40 screws


Recovery System

Drogue ParachuteFruityChutes CFC-181 in. tubular nylon, 50 ft.Terminal Velocity: 83.1 ft/s

Main ParachuteFruityChutes IFC-1441 in. tubular nylon, 50 ft.Terminal Velocity: 11.2 ft/s


Avionics

Two Stratologger CF

Drogue: Apogee / Apogee + 1s

Main: 600 ft. / 550 ft.

Inertial Measurement Unit (IMU):

Features accelerometer, gyroscope, magnetometer, and pressure sensor

Located in nose cone

Featherweight Raven3 altimeter

Records pressure (altitude), acceleration, and temperature



GPS Tracking

XBee-Pro S3B Radio Transmitter with Antenova GPS


Powered by CR123 lithium ion battery

Used with success on previous CRW flights

Transmitting frequency: 902 to 928 MHz

Transmits to distances up to six miles away


Mass Statement and Margin

Wet Mass: 50.095 lbm

Burnout Mass: 39.995 lbm

Difference from CDR estimates: 2.874%

Some 3D prints strengthened with greater infill percentage

Added nose cone tracker and avionics assembly


Flight Profile

Predicted Apogee: 5012 ft.

Max Velocity: 582 ft/s

Max Acceleration: 249 ft/s2

Velocity off Rail: 57.6 ft/s

Thrust to Weight Ratio: 6.91

Time of Flight: 99.7 s

Time to Apogee: 18.4 s


Flight Profile

Variable Wind Speeds:5 MPH: 5009 ft.

10 MPH: 5021 ft.

15 MPH: 5006 ft.

20 MPH: 4963 ft.


Trajectory Verification

Rocksim: 5012 ft.

OpenRocket: 4963 ft.

RASAero II: 4999 ft.

Custom Code: 4982 ft.


Trajectory Verification

Variables:Motor Impulse (±1%)

Rocket Mass (±0.25 lbf)

CD Error (±0.04)

Temperature (±15 oF)

Wind Speed (±2 MPH)

Normal Distribution

Average: 4982.7 ft.

27.5% fall outside CRW Requirement

0% fall outside SLI Requirement


Stability Margin

CP location: 91.1 in.

CG location: 77.2 in.

Stability Margin: 2.25


Kinetic Energy


Vehicle Component Mass [lbm] Kinetic Energy [lbf-ft]

Upper Airframe 17.56 34.20

Coupler 4.35 10.47

Lower Airframe 15.85 30.87

Descent Time

Vehicle Flight Demonstration:Total descent time: 80s

Apogee was 5017 ft.

Competition Launch:Expected descent time:

78.5s

Apogee Target: 4982.7 ft.


Drift Analysis

Total descent time: 80.0 s

Drift under 20 MPH: 2340 ft.

Assumes:

Apogee occurs over launch pad

Wind is 1D and constant

Parachute opening times are considered


Vehicle Demonstration Flight

February 9, 2019 at 12:37pm

Mean Temperature: 42 °F

Party Cloudy

Winds: 9 MPH NNE

Predicted Apogee: 4664 ft

Aerotech L1420 used



Apogee reached: 5017 ft

Drogue deployed at apogee

Main deployed at 600 ft AGL

Descent velocity

83.1 ft/s under drogue

11.2 ft/s under main

Drift from rail to landing: 924 ft

Time to apogee: 18.3 s

Time of descent: 80 s

Rail to landing drift: 924 ft



Predicted apogee was low due to inaccurate drag coefficient

Raven3 accelerometer resolution was too low to accurately estimate drag coefficient

Estimated drag coefficient equal to 0.375 using Rocksim


y = 3E-05x + 34.378R² = 0.6311

0

10

20

30

40

50

60

0 50000 100000 150000 200000 250000 300000 350000 400000

Acc

ele

rati

on

(ft

/s2)

Velocity2 (ft2/s2)

0

1000

2000

3000

4000

5000

0 20 40 60 80 100 120

Alt

itu

de

(ft

)

Time (s)

Preflight

Actual

Payload


Beacon Release

Use video feed to confirm location

Send command to release beacon

Payload Concept of Operation


UAV Flight

Vehicle Landing

Pre-Flight

Wait for affirmation to deploy

Check for GPS lock Check for Ground

station connection Check video

feedback

Autonomous flight to the FEA (100 ft Ascent, flight to the GPS location of FEA)

Piloted landing on to the FEA Fail safe return to last way point when

communication loss

Payload Deployment2 Send command to fire black

powder charges

Piston: Pushes the deployment sheath and the nose cone out of the body tube

Deployment sheath: Houses the UAV and unfolds to allow UAV to fly when pushed out of the body tube by piston

1

3

4

5

6 Piloted flight away

front the FEA

Fly away


Changes since CDRMounting plates printed from PLA instead of machined aluminum

UAV operates under one battery instead of two

Deployment sheath has a carbon fiber beam instead of aluminum

Added spring steel


Upper and Lower Mounting Plates

Mounting plates printed out of PLA

Heat-set inserts to reduce amount of hardware

PLA reduces weight compared to aluminum

Act as UAV structureAll electronics and brackets connect to the

platesUpper mounting plate dimensions are

5.125 x 9.7 inchesLower mounting plate is 2.25 x 5.5 inches


Battery Bracket

Bent from aluminum sheet metal

Attaches to the upper mounting plateLocated at the bottom of the UAV

Encases the undercarriage of the UAVHouses most electronics and wiring

Bracket is 2.5 x 6 inches


Power Switch

Turns off UAV during vehicle flightCuts radio transmission to the

UAV

Reduces power loss by UAV

Normally closed switch powers on after deployment as the arm unfolds

Pressing of the arm against the switch powers of the UAV


Arm Spring System

Located on the side of the upper mounting plate

Spring system is activated when UAV is deployed

Arms are pulled apart when they are clear of the sheath

Stopping posts align the arms for flightSpring helps lock the arms into

place


Beacon Release System

Located on the back of the UAV

Beacon holder restricts horizontal movement Solenoid restricts vertical movement

Solenoid fires, releasing beacon from the UAV on command


UAV Electronics


Flight Computer

Electronics Speed Controllers

Beacon Release Solenoid

FPV Video System

Telemetry Transceiver

Deployment Controller


Latch solenoid

Externally accessible power switch

Enclosed radio receiver and controller

Payload Integration with Vehicle


Ground Systems Interface

Mission Planner, an open source ground controls software used to establish telemetry and command the UAV

A joystick mapped to throttle, pitch, roll, yaw to fly the UAV

Failsafe for low battery, communication loss and GPS loss in place

Easily accessible command option for landing, arming , disarming and beacon release mapped to buttons on the UAV controller (joystick)

Camera link established through Ethernet connection to GrandStream encoder


Payload Demonstration Flight Plans


Payload Demonstrate Flight – March 9

Objective is to retain payload and deploy the UAV

No plans to fly UAV off of sheath

Plan to verify connection between UAV and ground station through live telemetry; this will also verify that the sheath unfolds, that the arms move to the correct position, and that the UAV receives power

Plan to verify ability to command the UAV by using UAV controller to release beacon while on the sheath

Safety

Safety Committee Focus for FRR

Final Safety Training

Additional Hazard Analysis of Environmental Concerns

Updated Mitigation Verifications for Risk and Hazard Assessment

UAV SOP Development for Demonstration and Testing

Development and Implementation of Full Scale Launch SOP


Safety Training


Number Training Topic Date

- CPR/AED/First Aid 10/4/18 – 10/19/18

1 Basic Emergency Procedures 10/18/18

2 Black Powder Testing and Motor Safety 10/30/18

3 Outreach Safety 11/1/18

4 Sub-Scale Launch Safety 11/15/18

5 Test and Demonstration Safety 1/22/19

6 Full-Scale Launch Safety 2/7/19

7 Basic Lab Safety 2/14/19

8 UAV Safety 2/21/19

9 UAV Laws and Regulations 3/5/19


Environmental Hazards

Environment vs System

Surrounding Land

Weather

Crowd

System vs Environment

Pollution/Litter

Surrounding Land

Airspace


Checklists and SOPs


Vehicle UAV

Sub-Scale Black Powder Demonstration Deployment Controller Demonstration

Sub-Scale Launch Thrust Test

Shock Cord Tensile Test Hover Demonstration

Fin Can Stress Demonstration Flight Range Demonstration

Kinetic Energy Drop Demonstration Deployment Ejection Demonstration

Black Powder Demonstration Field Deployment and Flight

Full-Scale Prep and LaunchLaboratory Checklist: LiPo Battery Charging

Procedure


Final Launch SOP Notes


Section Titles

Red Triangle for

Immediate Safety Note

PPE Reminder

Sections to be Conducted in

Parallel

Red Procedure

Note Reminder

Effect of Missing a

Step

Signatures at Completion of Section

Full Scale SOP: Pre-Launch


Pre-Travel Preparation Procedures

At Field Procedures

Upper Airframe Assembly Checklist

Ejection Charge Installation

Motor Installation

Final Checkout

Pad Checklist

Nosecone Checklist

Piston Checklist

UAV ChecklistPayload Integration

Checklist

Coupler Checklist

Lower Airframe Assembly Checklist

Recovery Checklist

Drogue Installation (Upper Airframe)

Main Installation (Lower Airframe)

Post-Flight Checklist

UAV FLIGHT OPS

Final Checklist

Full Scale SOP: UAV Deployment


Post-Flight Checklist

Hand Over of Operations to Payload

Red Team

Deployment Checklist

UAV Flight Checklist

Final UAV CloseoutEmergency Landing

Procedures

Program Management

Testing Overview

6 Vehicle TestsRecovery Charge Tests

Sub Scale and Full Scale Flight Demonstrations

Recovery Harness Tensile Stress Test

Drogue Deployment Kinetic Energy Test

5 Deployment TestsTwo Electronic Tests

Payload Ejection Test

Orientation Test

Integrated Deployment Test

6 Payload TestsTwo Electronic Component Tests

One Propulsion System Thrust Test

Three Flight Tests


Vehicle Testing ProgressTest Name Description Status Outcome

Subscale Recovery

Charge Test

Verify black powder deployment

charges adequate to deploy

parachutes

Complete Successful

Subscale Flight Test Complete Successful

Full-Scale Recovery

Charge Test

Verify black powder deployment

charges adequate to deploy

parachutes

Complete Successful

Recovery Harness Stress

Test

Determine if the shock chord will

maintain structure at flight

loading

Complete Successful

Drogue Deployment

Drop Test

Determine if deployment system

shear pins remain intact during

flight loading

Complete Successful

Fin Can Stress Test

Determine if flight forces would

cause damage to removable fin

can

Complete Successful


Deployment Testing Progress

Test Name Description Status Outcome

Deployment Electronics

Test

Verify deployment electronics

function as commanded.Complete Successful

E-Match Deployment

Test

Verify deployment electronics

successfully ignite e-match.Complete Successful

Deployment Black

Powder Test

Verify deployment black powder

charge can successfully deploy

dummy mass

Incomplete

Deployment

Orientation Testing

Verify sheath can orient payload

on a variety of landing

orientations

Incomplete

Integrated Deployment

Test

Test deployment ejection and

payload orientation with payload.Incomplete


Payload Testing Progress

Test Name Description Status Outcome

FPV TestTest image quality, transmission

range of FPV Camera.Complete Successful

Telemetry Range TestVerify telemetry transmits at

required distancesComplete Successful

Integrated Propulsion

Test

Test thrust level of payload in its

flight configurationPartially Complete Partially Successful

Flight TestTest tethered and free flight of

vehicleIncomplete

Flight Endurance Test

Ensure payload has sufficient

power to meet requirements for

flight.

Incomplete

Flight Range TestingEnsure payload can fly required

distance with sufficient battery.Incomplete


Testing Spotlight – Deployment Test


Tested Deployment Ejection System

Stepped up charges from 0.5 to 1 to 1.5 to 2.25 grams of black powder

Ejected the deployment sheath fully, but caused damage to deployment system


Requirement

NumberRequirement Description Compliance Verification Plan Verification Status

NASA-5.5 Teams will abide by all rules set forth by the

FAA.

All applicable FAA regulations are accessible to the

team. The Safety Officer and Team Leadership are

responsible for ensuring CRW is in compliance with all

applicable FAA regulations.

Lists of the applicable FAA regulations are available to the team on the

CRW online sharing site. Team Leadership ensures all applicable FAA

regulations have been considered when in the design phase of the

project.

Inspection complete

UAH-V-01 The vehicle shall reach an apogee of 4800

feet within ± 250 feet

Simulations were used to predict an achieved altitude of

4806 feet. The subcale test flight was used to refine the

simulations.

Analysis

The team will use simulations and hand calculations to confirm that

vehicle will reach the required height.

Complete

The simulations predict the launch vehicle will

reach 4806 feet.

UAH-V-02 There shall be redundant, increasing black

powder charges in the event of initial

recovery system deployment failure.

Multiple increasingly powerful black powder charges

will be installed in the recovery system.

Analysis

The launch vehicle will incorporate redundant black powder charges.

Incomplete

The subscale rocket incorporated redundant black

powder charges. The full-scale rocket is awaiting

assemblly.

Requirement Verification & Compliance


Verified using the method below

Validated through testing, demonstration, analysis, or inspection

Example displayed below

Outreach Events


Event DateStatus:

PurposeAnticipated Number of Individuals

St. Francis Borgia Regional High School

Oct. 12 Completed Present Rocketry Basics 37

Girls Science… Nov. 3 CompletedPresent about Friction and

Rocketry Basics166

First Lego League Nov. 10 CompletedInteraction with parents

and students72

Interactive Rocketry at Lexington High School

Nov. 28 Completed Present Rocketry Basics 174

Interactive Rocketry at Elkhorn Crossing School

Dec. 11 Completed Present Rocketry Basics 147

Eagle River High School Dec. 12 Completed Interaction with Students 26Canyon Crest Academy Dec. 20 Completed Engineering Design Activity 29

Science Olympiad Feb. 14 Completed Interaction with students 56UAH’s Take Your Daughters … Feb. 18 Completed Rocketry Basics Activity 90

Hewitt Trussville High School Feb. 22 CompletedPresent rocketry basics &

Open Rocket212

Ramsay High School Mar. 11 Planned Present rocketry basics 75Total Impacted 1,084


Funding Status


Funding sources have not changed since CDR

New funding status displayed to the right

$550.00 refund to UAH USLI Foundation

Projected vs. Actual Expenditures



Future Events


Deployment Re-TestingMarch 07 (Huntsville, AL)

Hover Test March 07 (Huntsville, AL)

Payload Demonstration Flight March 09 (Huntsville, AL)

Remaining Flight Testing March 11 – March 15

Questions

Appendix

Deployment Testing ProgressTest Name Update (12 March, 2019)

Deployment Black Powder Test Added 1 inch joint reinforcement to

add surface area of epoxy bond

between piston bulkhead and piston

shoulder. Settled on 2 gram black

powder charge.

Issues with solenoid, investigating

causes.

Deployment Orientation Testing Deployment testing has been

completed. The test was successful.


Payload Testing ProgressTest Name Update (12 March, 2019)

Integrated

Propulsion

Test

Test thrust level of payload in its flight configuration

Flight Test Tethered flight testing has begun. UAV has adequate

thrust to lift off. Problems with commanded take off

has prevented sustained hover.


nasa usli flight readiness review...connor gisburne, payload safety lead dr. david lineberry,...

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